Automated Bag in Box Assembly and Contents Fill

ABSTRACT

A BIB carton ( 150 ) conjoins a bag ( 12 ) with a carton ( 11 ) preparatory to carton fill, with an intervening locating collar ( 14 ) upon a bag neck upstand ( 52 ); 
     an assembly and fill process brings successive individual cartons ( 41 ) into juxtaposition with a bag ( 51 ) in a continuous bag web ( 55 ), using the neck ( 52 ) for alignment and registration; 
     a locating retention collar ( 14 ) is applied to secure bag neck ( 52 ) to carton ( 41 ), to create a sub-assembly web stack ( 71 ) of conjoined flat-pack BIB cartons ( 20 ); 
     an inflation (test) station ( 110 ) retrieves these sub-assemblies ( 20 ) and inflates/fills them via successive valve caps ( 111 ) secured to collars ( 14 ); 
     bag ( 51 ) inflation/fill causes carton ( 41 ) formation around it, before a taping machine closes and seals top ( 56, 42, 48 ) and bottom ( 57, 58 ) carton flaps.

In GB0314815.2, the Applicant has proposed a particular implementationof a so-called Bag-In-Box (BIB) container.

Generally, BIB designation is applied to an impermeable bag liner withina carton.

To that broad proposition, the Applicant has contributed an interveningneck collar locating, bracing and support element.

This collar feature allows:

-   -   accurate mutual registration or (self-)alignment of bag liner        and carton outer;    -   transfer, distribution or sharing of bag and carton loading by        bag neck capture through a collar—itself supported in a bespoke        carton recess or cut-out; and    -   retention of the bag neck to allow torque closure of a screw        cap.

Bag Contents Fill

GB0314815.2 sets out fill issues.

Thus, bag contents fill is a prime consideration for a contentsmanufacturer.

Generally, dedicated automated filling lines are employed for a bespokeBIB configuration.

Traditional bag fill typically prefaces insertion of a filled bag into apre-formed carton assembly.

Insertion and cartoning themselves can be a mix of manual and mechanisedsteps.

Fill Machinery

Resources commitment inhibits packaging change, if incompatible withestablished filling machinery.

Hitherto, fill machinery for (semi-)rigid walled containers, such asblow moulded Jerrycans, has (often) been incompatible with that for BIBcontainers.

A wet fill environment, with contents spillage, and risk of degradingcardboard cartons is a factor.

Mechanised Erection

Mechanised carton case erection generally is well developed for closingand joining carton flaps with tape and/or adhesive bonding.

However, cartoning mechanisation has not hitherto been integrated withautomated bag filling.

Indeed bag presentation for fill and fill itself have traditionally beenundertaken as separate steps, preparatory to bag insertion in a largelycompleted carton, aside from top closure flaps.

Bag Pre-Fill

In conventional BIB production, a bag is pre-filled and inserted (ordropped) into a partially erected carton, which is then closed aroundit.

An object of the present invention is to admit alternative BIB fill anderection techniques.

STATEMENT OF INVENTION

Some aspects of the present invention address refinement in production,assembly, erection and filling of BIB containers and component elements.

Certain variants in BIB design and construction are also envisaged.

Particular instances include:

-   -   supplementary pre-fabricated handles—desirably a ‘lay-flat’,        single sheet, fabrication;    -   a deformable cushion floor able to withstand crushing, collapse        and failure upon dropping;    -   a bracing liner or sleeve;    -   top and bottom end stacking plates;    -   air cushion bag;    -   pressure release valve effect;    -   integrated neck collar and handle moulding;    -   plastics sheet carton;    -   neck collar integration with plastics sheet carton;    -   integrated bag neck and location collar.

According to one aspect of the invention, a BIB is assembled from a bagliner and carton, juxtaposed—and mutually entrained—such as by a bagneck retention rim—prior to bag (contents) fill.

Rectangular 3-D Bag

A preferred bag format has a generally rectangular, flat bottom, 3-Derect configuration, for closer conformity with a rectangular cartonouter case.

Continuous Bag Web & Discrete Carton Blanks

A continuous web of collapsed bag portions with respectivefill/discharge necks is conjoined with a succession of multiple discreteformative carton elements such as collapsed carton blanks.

Locating Collar

A locating collar, such as of GB0314815.2, is desirably fitted upon abag neck.

Such a collar can overlie an inset step or recess in a carton (top) endflap, and sit beneath a neck retention rim, flange or lip.

This gives an anti-torque seat, which resists bag neck turning uponscrew closure cap fitting and removal.

Side wall panels of carton blanks are wrapped around collapsed bags,preparatory to flap joining.

Local adhesive bonding, taping and/or interlocking edge profiling may beemployed.

Handle

An optional pre-fabricated handle element may be attached to the cartontop or side panels.

The handle is desirably a ‘lay-flat’, single sheet, fabrication.

Alternatively, an integrated handle and collar top-plate may be fittedto the carton.

Sub Assembly

This creates an intermediate sub-assembly which may adopt and preserve acompact, 2-D collapse-folded, flat-pack, configuration preparatory tofinal erection into a 3-D enclosure, assembly and fill.

This sub-assembly lends itself to compact storage and transport to aremote final erection, assembly and fill stage.

Erection by Bag Inflation

BIB container 3-D erection, from a collapsed 2-D form, is achieved byintroducing fluid—say air—under pressure through a bag neck, to inflatethe bag.

Bag inflation takes a carton shell along with it—through snap-actionerection about pre-formed carton edge creases/folds—until the cartonassumes a pre-disposed (rectangular) volumetric form.

Thus a collapsible flat-pack, but otherwise (sub) assembled BIBconfiguration can be contrived.

This preserves compact collapsed flat-pack (sub-) assembled format forspace-efficient storage and shipment—rather than shipping a bulkycontainer void, as with, say, a traditional Jerrycan.

On-site erection could be undertaken at a fill station.

That said, pre-assembly and erection to an empty BIB carton form can beundertaken preparatory to shipment to a remote fill station.

Bag/Carton Clearance Void

Generally, it is advantageous to preserve a certain ‘clearance void’between carton and bag, to allow relative bag displacement upon impact.

Cushion Floor

A collapsible cushion floor pad insert may be inset between an outercarton and inner bag to bolster shock absorbency in the event of cartondrop.

A deep or multi-layer corrugated cardboard sheet sandwich layer mayfulfil this role.

Otherwise there is a risk of bag rupture and contents bursting uponlocal carton wall deformation or failure.

Cushion (Air) Bag

Features of a clearance void and cushion floor could be combined in acushion bag—that is a discrete, say air inflated, capsule betweencontents bag proper and carton base and/or top.

Such a cushion bag could also be integrated with a contents bag proper.

An example would be a double-wall or skin.

Effectively, a bag would constrain contents within an inner liner andentrain (cushion) air between inner and outer liner.

Such an air capsule could compress more readily than liquid contents andso form an intermediate, energy dissipating, shock absorbing buffer.

Such a configuration may be particularly useful for relatively largecapacity (eg some 25 litre) BIB variants.

Alternatively, a discrete self contained subsidiary (air) cushion bagcould be carried or attached to the contents bag proper.

Preferably, such a cushion bag would be inflated prior to insertion intoa carton.

Release Valve

A preset blow-off valve could allow controlled discharge of a buffercapsule upon a certain compression load threshold.

In practice, a carton top recess or step, for a locating collar, couldserve as a safety displacement element upon BIB drop.

Thus, upon carton crush from below (i.e. upon drop) the bag within isdisplaced upward.

This in turn forces outward a carton recess and entrained neck collarand bag neck—for less constrained bag displacement.

Otherwise, were a carton a solid rectangle, a bag would have nowhere toredistribute—and would be forced against the carton top, with risk ofcarton and/or bag burst.

Reinforcement/Bracing Sleeve

A supplementary reinforcement or bracing sleeve or collar may be fittedbetween carton and bag, to help absorb shock impact load.

A deep or multi-layer corrugated cardboard sheet sandwich sleeve mayfulfil this role.

This obviates changing entire carton wall gauge for exceptionalconditions.

Corrugated Carton

Indeed an entire carton could be fabricated from corrugated thick wallcardboard for an inherently very robust construction—which could obviatethe need for a bracing liner.

Plastics Sheet Carton

Thin sheet, laminated or corrugated synthetic plastics material might beemployed for specialist application where economics justify.

Features such as a neck collar and/or handle could be integrated intosuch plastics sheet, say by local (vacuum) moulding or die cutting, withjudicious use of heat to soften material.

Rectilinear Grouped Form

A regular, rectilinear, and in particular rectangular, carton format,with neck inset within a neck collar in a top panel recess or cut-outallows closely inter-nested rectilinear grouped stacking and packing.

Such rectilinear grouping admits of more orderly shipment than, say,rounded edge Jerrycans with irregular top surfaces with protruding fillnecks.

Mixed Carton Sizes

Mixed size cartons of proportionate scaled relative volume and sizemultiples can be stacked together—without undermining stability or spaceutilisation.

Cluster Pack

Clustered or grouped multi-packs can be part enshrouded by a commonwrap, sleeve or minimal opposed (top and bottom) cluster or stackingplates, say entrained by tie bands.

Shrink Wrap Palletisation

Larger and multi-layered stacks can be grouped upon a common pallet.

Collective shrink-wrapping of such a palletised stack creates a unified,robust, load shipping format.

A strictly rectangular outer profile and careful relative sizing andproportions allow intimate wall surface contact—and so mutual bracing ina stack.

Collective Scaled Print Image

With homogenous, abutting, carton forms, an entire carton surface can beover-printed, so a grouped carton collection can portray an enlargedgraphic image from individual carton elements.

Such a jigsaw image effect could be used to cross-check correct cartongrouping and alignment.

Leak Test

Bag pre-inflation could be used as a pressurised leak test, bymonitoring inflated bag sealing integrity, prior to filling.

To this end a bag could be subjected, albeit temporarily, to somewhathigher pressures—or pressure differentials across a boundary wall—thanit would normally be expected to withstand.

Aside from identifying (and so preempting from operational use) ruptureand burst vulnerabilities, such as along heat weld seams, lesser, albeitlonger term insidious leakage, such as between neck and bag joint, canbe assessed, by monitoring the ability of a bag to sustain a given startpressure.

A valve in a fill head could allow both functions in a single bag neckcapture through one-way fill and opposite way exhaust, with ameasurement gauge tapping to the bag interior.

Such functionality could be achieved by bespoke design or adapting anotherwise conventional so-called ‘plunging or diving head’ filler.

A fill head, with integrated check valve, makes temporary sealingcontact with a bag neck or neck collar for a fill cycle.

Reject Disposal—Recycling

In an automated erection and test line, provision could be made tooff-load a rejected ‘failed’ bag, say by releasing it to a wastecollection hopper.

Collected bags could be disposed of by plastics recycling.

The nature of the bag plastic lends itself to recycling more than, say,semi-rigid walled Jerricans.

Any entrained carton with a rejected bag could be released and, ifundamaged, returned to a sub-assembly line for re-use—or simply disposedof by cardboard recycling.

Contents Fill Inflation

Although bag inflation for outer carton erection can be undertaken as anintermediate step, preparatory to contents fill, that fill step coulditself be used for initial inflation and erection.

That is, the bag could remain collapsed until final fill.

Progressive Fill

Uninflated bag capacity is initially at a minimum and offers modestresistance until an inflated internal void is created upon bag erection.

To reflect this, a progressively increasing fill pressure and/or flowregime could be adopted.

This would obviate bag shock, fill line blow back and trigger ofover-pressure release valves.

This also allows the inflating bag to take an outer carton form alongwith it from a collapsed 2-D flat-pack to an erect 3-D form.

If fill rate is a priority, more abrupt and faster, pre-erection, suchas by air inflation can be employed.

EMBODIMENTS

There now follows a description of some particular embodiments ofautomated BIB assembly and contents fill according to the invention, byway of example only, with reference to the accompanying (diagrammaticand schematic) drawings, in which:

FIG. 1 shows a flow chart of principal operational steps in BIBconstituent element assembly;

FIGS. 2A and 2B show a BIB sub-assembly sequence;

More specifically,

FIG. 2A shows a schematic BIB sub-assembly sequence;

FIG. 2B shows a flow chart of principal operational steps in thesub-assembly sequence of FIG. 2A;

FIGS. 3A and 3B show BIB erection and final assembly;

More specifically,

FIG. 3A shows a schematic BIB erection assembly from the sub-assembly ofFIG. 2A;

FIG. 3B shows a flow chart of principal operational steps in theerection and final assembly sequence of FIG. 3A;

FIG. 4 shows multiple simultaneous pre-inflation and/or fill detail inthe erection and final assembly sequence of FIGS. 3A and 3B;

FIGS. 5A and 5B show variant BIB sub-assembly and erection sequences;

More specifically,

FIG. 5A shows a continuous segmented carton web fed variant BIBsub-assembly sequence to that shown in FIG. 2A;

FIG. 5B shows a variant BIB erection sequence to that shown in FIG. 3Ain continuation of FIG. 5A sub-assembly;

FIGS. 6A and 6B show optional insertion of elements during the erectionand final assembly sequence of FIG. 5B;

More specifically,

FIG. 6A shows insertion of a cushion floor into the carton before finalend flap closure;

FIG. 6B shows insertion of a reinforcement or bracing sleeve into thecarton before end flap closure;

FIGS. 7A and 7B show optional rectilinear grouping of erect BIBassemblies employing top and bottom stacking plates entrained by tiebands;

More specifically,

FIG. 7A shows the rectilinear grouping of similar sized BIB cartons;

FIG. 7B shows the rectilinear grouping of different sized BIB cartons;

FIGS. 8A and 8B show further variant BIB sub-assembly and erectionsequences;

More specifically,

FIG. 8A shows a variant BIB sub-assembly sequence to that shown in FIG.5A, from respective rolled carton and bag webs;

FIG. 8B shows a variant BIB erection sequence to that shown in FIG. 5A,employing the sub-assembly of FIG. 8A;

FIGS. 9A through 9H show a variant BIB assembly sequence;

More specifically,

FIG. 9A shows a carton blank element;

FIG. 9B shows the carton blank of FIG. 9A configured to form a tube wrapor sleeve;

FIG. 9C shows the carton of FIG. 9B with closed top flaps;

FIG. 9D shows (pre-) inflated and/or filled bag insertion into thebottom of the carton of FIG. 9C;

FIG. 9E shows the combined carton and bag of FIG. 9D with closed bottomflaps and a collar fitment;

FIG. 9F shows the assembly of FIG. 9E with collar in place.

FIG. 9G shows the assembly of FIG. 9F with optional handle attachment;

FIG. 9H shows the assembly of FIG. 9G with optional integrated handleand collar top-plate;

FIG. 10 shows a further variant BIB assembly sequence of multiplediscrete carton wrap and fold around respective discretepre-inflated/filled bags—before collar and optional handle attachment;

FIGS. 11A through 11C show a variant BIB sub-assembly sequence to thatshown in FIGS. 2A, 5A, and 8A;

More specifically,

FIG. 11A shows in detail an unrolled web of contiguous bags overlaid byindividual carton blanks before collar attachment;

FIG. 11B shows a carton blank wrap around a bag;

FIG. 11C shows the arrangement of FIG. 11B with completed carton wraparound a bag and edge joined;

FIGS. 12A and 12B show entrained box or carton and bag sub-assemblies,in a stackable flat-pack configuration, ready for transport, storage orerection and contents fill;

More specifically,

FIG. 12A shows an individual carton and bag set upright—in this instancewith bag outside a carton wrap ready for insertion through a topopening;

FIG. 12B shows stacked cartons and respective bags—allowing a bag setwithin a carton wrap;

FIGS. 13A through 13C elaborate upon bracing sleeve insertion into acarton of FIG. 6B;

More specifically,

FIG. 13A shows an erected bracing sleeve liner juxtaposed for insertioninto an open-ended top of a carton;

FIG. 13B shows a completed BIB carton with internal bracing sleevedepicted in broken lines;

FIG. 13C shows an enlarged view of a corner of the bracing sleeve ofFIG. 13A, showing corrugated material;

FIGS. 14A and 14B show a robust carton variant fabricated entirely ofcorrugated card (or plastics);

More specifically,

FIG. 14A shows a corrugated carton with open top flaps;

FIG. 14B shows an enlarged view of the corrugations in the carton ofFIG. 14A;

FIGS. 15A and 15B show an inset collar recess or step outward reversal,acting as a safety valve upon BIB (drop) impact;

More specifically,

FIG. 15A shows initial BIB drop impact with resultant carton bottom(corner) crush deformation;

FIG. 15B shows resulting collar recess ejection and support step outwardhinge, admitting bag displacement;

FIG. 16 shows a BIB variant with internal top cushion (air) bag;

FIGS. 17A through 17C show insertion of an integrated bag and collarinto an erect carton;

More specifically,

FIG. 17A shows bag and carton juxtaposition;

FIG. 17B shows bag profile squeeze insertion through a carton topopening; and

FIG. 17C shows a final bag in carton assembly;

FIG. 18 details collar and bag anti-torque restraint within a cartonrecess for screw closure cap tightening and loosening;

FIGS. 19A and 19B show a synthetic plastics sheet carton variant withintegral moulded collar;

More specifically,

FIG. 19A shows a sheet plastics carton blank with integral mouldedcollar;

FIG. 19B shows the sheet plastics carton blank of FIG. 19A fullyerected;

FIGS. 20A and 20B show a variant of the sheet plastics carton of FIGS.19A and 19B—with additional handle cut-out;

More specifically,

FIG. 20A shows a sheet plastics carton blank with integral mouldedcollar and handle cut-out;

FIG. 20B shows the sheet plastics carton blank of FIG. 20A fullyerected.

Referring to the drawings . . .

Constituents

FIG. 1 depicts an assembly sequence flow chart of principle constituentBIB elements, namely:

-   -   box or carton 11;    -   bag 12;    -   locating neck collar 14—per GB0314815;    -   (optional) discrete (side/top) handle 13;

The bag 12 features an integral neck pourer or spout for contents filland discharge.

A preferred bag manufacture (not shown) produces a continuous web ofmutually edge-entrained, collapse folded bags.

That said, discrete bags (say either produced individually or separatedfrom a web) can be used, as discussed in later embodiments.

Handle—Handling

Generally, for handling ergonomics, discrete neck collar 14 and handle13 are disposed at opposite sides of a carton body 11.

A handle allows a user both to support filled weight and control theangle of tipping—and so rate of pouring.

A tall (say, pull-up) handle upstand at the neck collar 14 is feasible.

Supplementary handle cut-outs in the body (that is top and/or sidewalls) of carton 11 are readily provided upon carton blank die cutting.

In some variants, the collar 14 and handle 13 could be integrated—say byadopting a common (vacuum) moulding plate or strip.

Such an integrated handle and neck collar could form an overall cartontop plate, providing shape bracing and support to a stacked overlyingcarton.

Flat Pack Sub-Assembly

These various elements are brought together in a compact collapsed,flat-pack sub-assembly 20—for ‘dense’ (ie space efficient) bulk stackingand packing, to supply a remote fill station.

Final pack erection and completion (closure and sealing), to a pre-fillassembly 30, can be undertaken upon sub-assembly 20 in a subsequentdistinct step at a fill station, on a user's premises, upon draw-downfrom a local store or repository.

Thus a fully erect 3-D volumetric form is not assumed until necessary toaccommodate contents.

In this schema no wasteful void space is consumed in transport orstorage until call-off just preparatory to fill.

However, if space is not at a premium, empty erected forms can betransported and stored—relieving the fill plant of the need for aninflation/erection station.

Automated Assembly

Although special-purpose machinery and operation is involved with BIB,certain (sub-)assembly steps can be derived by adaptation ofconventional case erection packaging machines and technology.

This represents an economic advantage if a user is converting fromtraditional semi-rigid walled cartons to BIB, but already has certainpackaging equipment.

The drawings are thus intentionally merely indicative and illustrativeof broad principles, rather than necessarily detailed engineeringsolutions.

Sub-Assembly

FIGS. 2A (conveyor side elevation) and 2B (sequenced flow chart) depictin more detail creation of sub-assembly 20 of FIG. 1.

Bag Web

Bags are produced as continuous web 55 of conjoined individual bagelements 51.

A web 55 of conjoined bags 51 is stored concertina-folded in a cassettestore or repository 50.

The bags 51 are progressively retrieved from the store 50 by orderlyunfolding and presented in a line, with necks 52 uppermost, upon aconveyor bed 80.

Carton Stack

Multiple discrete cartons 41 are stacked, one above another incorresponding orientation, as individual cut pre-folded carton blanks,in a cassette store 40, ready for individual pick-off and deposit upon acorresponding individual bag 51.

Carton Blank

FIG. 9A shows laid-flat carton blank detail, with extended top 42, 48,56 and bottom 57, 58 closure flaps and optional handle cut-outs 44.

The span of bottom side flaps 57 allows mutual overlap upon flap foldup—to cover the whole of the base area.

Bottom end flaps 58 then fold over—to provide three complete layers ofmaterial on the base and thus bolster carton robustness.

End flaps 58 are off-set (i.e. one longer than the other) to mirror theoff-set of the top flaps 42, 48 in accommodating the collar 14.

Thus a single off-set tape machine (not shown) may be used(simultaneously) to seal both top 42, 48 and bottom 58 flaps.

Neck Aperture

A carton top flap 42 has a pre-cut neck aperture 43 to receive andlocate a neck 52 of a bag 51.

Neck aperture 43 diameter is sufficient to pass, with modest localdistention, and remain entrained under, a retention rim (not shown) uponbag neck 52.

Radial slits (not shown) about aperture 43 create locally a segmentedperiphery for such distension.

Pick'n Place

A pick'n place arm (not shown) deposits an individual carton 41 upon anassociated bag 51, with the help of lateral conveyor guides 81 and anindex locator finger (not shown) for a bag neck 52.

By drawing bag web 50, successive bags 51 are 00indexed, incrementallyor continuously, over conveyor bed 80, through successive work stationsfor carton 41, collar 14 and (optional) handle 13 fitment.

Collar

A cassette store 60 of stacked pre-fabricated (eg vacuum moulded shell)neck collars 14 is disposed over the conveyor 80 to deposit anindividual collar upon an upstanding bag neck 52.

Collar 14 is superimposed upon a carton top flap 42.

A collar aperture 61 is sufficient to pass, with modest temporary localdeformation, over neck retention rim—so that both carton top flap 42 andcollar 14 are held captive between retention rim and bag 51.

Collar aperture 61 profile can be adapted—say with radial peripheralslits or otherwise segmented—to facilitate local distension for fitmentand to secure bag neck 52 when a screw cap is applied.

The effect is to impart an anti-torque or torque resistant entrainmentof bag neck in relation to (screw) cap closure fitment.

Handle

A supplementary discrete handle 13, can be fitted to a carton top flap42 and side edge 45 at a handle installation station 90.

A pre-fabricated (moulded) ‘lay-flat’ profile is convenient for handle13.

Such a handle 13 can be secured by local adhesive bonding.

In addition, or alternatively, reliance can be placed upon handlecut-outs in the carton body.

In some variants, handle 13 could be integrated with collar 14—in whichcase a combined store and mounting station could be contrived.

Concertina Stacking

Carton 41, bag 51, neck collar 14 and (optional) handle 13 are fitted tocreate a sub-assembly 20.

A succession of sub-assemblies 20 is mutually entrained in asub-assembly string or web 71,

Web 71 is drawn into a concertina-folded stack in a sub-assemblycassette store or repository 70.

Sub-Assembly Review—Overview

Flat Pack

The overall assembly sequence involves:

-   -   bringing together into juxtaposition a collapsed bag 51 and        collapsed carton 41,    -   with insertion of an intervening location collar 14 according to        GB0314815,    -   so preserving a compact collapsed flat pack individual        sub-assembly 20 form in a sub-assembly string 71.

A bag neck 52 of an individual bag 51 is orientated upward as an upstandfor registration and location of an aperture 43 in a top flap 42 of acarton 41.

An automated BIB carton assembly line 100 is fed by a continuous web 55of bags 51 and a stack 40 of collapsed cartons 41.

A conveyor 80 draws the web 55 along an assembly path, at whichsuccessive individual cartons 41 are extracted from the stack 40 andlaid upon an associated bag 51.

A carton 41 is presented to an underling bag 51 with a top flap 42 andneck locating aperture 43 deployed in mutual registration.

Side and/or end flaps 46 are in-turned and joined, using tab 19, tocreate a carton sleeve or wrap 47 about each bag 51.

This leaves top 42, 48, 56 and bottom 57, 58 (closure) flaps to bedeployed and mutually entrained—upon conversion from a 2-D collapsedform to a 3-D erect form.

A collar storage cassette 60 with a discharge driving plunger (notshown), delivers and installs individual collars 14 to each bag neck 52,with a spring clip insertion and location action.

Collar 14 effectively holds the carton top flap 42 with neck locatingaperture 43 captive with the bag neck 52—and thus entrains overallcarton 41 and bag 51.

The bag neck 52 serves as a locating upstand, to help preserve bag 51and carton 41 registration and alignment—also aided by lateral conveyorguides 81.

Thus successive cartons 41 are entrained upon respective individual bags51 of the bag web 55.

The entrained bag web 55 and carton ‘string’ 71 is concertina folded ina storage cassette 70.

Storage cassette 70 is conveniently a portable container, which can betransported to a remote final assembly and fill station, as nowdescribed.

Collapse Folded Flat Pack Sub-Assembly

The overall outcome of FIGS. 2A and 2B sub-assembly stage is a compact,collapsed-folded, flat-pack of mutually entrained or captive bag 51,carton 41, neck collar 14 and (optional) handle 13, in a sub-assemblystring 71.

Final Assembly & Erection

FIGS. 3A and 3B depict final assembly and erection to transform a 2-Dcollapsed flat pack sub-assembly 71 of FIG. 2 into an erected fullyassembled 3-D form 150 ready for contents fill.

Preparatory Bag (Test) Inflation

In this schema, an intermediate preparatory bag (test) inflation isundertaken preparatory to carton 41 closure fully to envelop the bag 51.

Contents Fill

In an alternative schema, initial bag 51 inflation is through contentsfill—that is bypassing a preliminary test inflation.

The sub-assembly cassette store 70 is emptied by progressivelywithdrawing a sub-assembly string 71 based upon an original bag web 55.

Individual bags 51 are presented to a preliminary inflation test station110 with necks 52 uppermost.

This orientation also corresponds to the stacking orientation at theconclusion of the sub-assembly stage of FIG. 2.

Bags 51 are supported by a conveyor bed 120.

Simultaneous connection is made to multiple bag necks 52 throughmultiple individual valve caps 111, with respective umbilical feed pipes112 to an air pressure supply 113, through a rotary swivel connectorvalve 114 (detailed in FIG. 4).

Individual bags 51 are captured with a valve cap 111 and a retention rimlocating collar (not shown) to bear bag 51 and contents weight.

Until fitment of valve cap 111, and capture by a neck retention rimlocation collar, successive bags 51 remain mutually entrained inoriginal continuous bag web 55—and are thus to an extentself-registered.

Upon valve cap 111 and rim locator fitment, bags 51 are mutuallysevered—so breaking or fragmenting the former continuous web 55.

Severance is conveniently undertaken along a pre-scored weakening line,using a (slicing rotary or guillotine) knife blade (not shown).

Upon mutual severance, individual bags 51 are free to adoptedindependent positions and orientations in relation to successive,formerly adjoining, bags 51.

Whilst a bag 51 is held captive by its neck 52, its body is free to hangdown—suspended by retention rim, itself configured to withstand suchsupport loading.

Similarly, a carton 41 is held captive by entrapment of its top flap 42beneath the bag retention rim.

However, the bulk of carton 41 is free to swing down about a top flapcorner edge fold 49.

Air (Pre-Fill) Inflation

Bag 51 and carton 41 gravity suspension is triggered by air pressurefeed to cap valve 111—progressively to inflate, and so distend bag 51walls from a collapse folded 2-D condition to an erect 3-D form.

Air Pulse

An air pulse can be employed to disturb initial juxtaposed bag 51 andcarton 41 disposition.

Successive individual separated bags 51 are carried upon conveyor 120 toan end flap closure station 130 and onward to a contents fill station140.

Multiple Pre-inflation/Fill

FIG. 4 shows a plan view of multiple simultaneous pre-inflation and/orfill detail in the erection and final assembly sequence outlined in FIG.3A.

A spider web array of fill lines 112 radiates from a common central feedhead 113 with a swivel joint and seal.

Individual fill caps 114 traverse a continuous orbital track 120.

Concertina Folded Bags and Cartons

FIG. 5A shows an alternative sub-assembly sequence to that of FIG. 2A.

In this arrangement, both bags 51 and carton blanks 41 are broughttogether from separate respective stacked concertina folded webs.

Once a carton 41 has been correctly located onto bag 51, it will besevered from subseqent carton 41 to enable individual carton 41 foldaround a respective bag 51, remaining in bag web 55.

As before, neck retention collar 14 is attached and the resultingsub-assembly 71 is concertina folded for transport or storage.

FIG. 5B shows a follow-on inflation/fill final assembly sequence to FIG.5A sub-assembly, with options supplementing basic steps of FIG. 3A.

These options are depicted schematically as interventions—themselvesdetailed in FIGS. 6A and 6B.

Again, concertina folded sub-assemblies 71 are drawn from their stackand attached to an air hose/feed line before being severed from the nextin line.

A bag 51 is then inflated/filled while the assembly is supported by itsretention collar 14.

This allows carton 41 to take shape as bag 51 volume increases.

A final step is to close and seal top 42, 48, 56 and bottom 57, 58carton flaps.

Cushion Floor

FIG. 6A shows an optional final assembly stage—prior to closure ofbottom carton flaps 57, 58—of insertion of a cushion floor 15.

Such a floor 15 may be comprised of corrugated cardboard or likematerial, to help protect the bottom of bag 51 inside carton 41.

Thus, carton 41 base puncture or crush may be accommodated by thecushion flooring 15 and thus preserve the bag 51 intact.

Reinforcement/Bracing Sleeve

Alternatively, or additionally, a reinforcement or bracing sleeve orliner 16 may be inserted into carton 41 before final closure, asdepicted in FIG. 6B.

Bracing sleeve 16 bolsters overall carton strength and rigidity forlarger and heavier capacties.

This is achieved without adoption of a higher or thicker grade cardboardfor the entire carton body.

Thus, a bracing sleeve could be corrugated to provide vertical stackingstrength, whilst an outer (non-corrugated) carton body provides splashand water protection.

Conversely, a corrugated carton body could make a bracing sleeveredundant.

Sleeve 16 also preserves overall rectangular carton form, for stackingconsistency and protects bag 51 in the event of carton 41 side impact.

Stacking Plates

An optional step of grouping and packaging multiple BIB cartons afterindividual carton (150) erection is reflected in FIGS. 7A and 7B.

Top and bottom stacking plates 17 sandwich multiple—in this case dual orpaired—adjacent BIB cartons (150) in a rectangular configuration.

Plates 17 are held together by tie bands 18 wrapped around the set atseveral points.

A final multiple (in this dual or paired) pack cluster option isdepicted in FIG. 7A.

This principle may be employed not for mutually entraining and securingidentical BIB cartons (150)—but also sets of different sized cartons,scaled and stacked to form a substantially rectangular outer form—asshown in FIG. 7B.

Web Rolled Bags and Cartons

FIGS. 8A and 8B show a variant of FIGS. 5A and 5B, whereby the bags 51and cartons 41 are brought together from individual web rolls 91, 92.

Thus, bags 51 are successively unravelled from roll 91, whilstcartons—possibly of synthetic plastics material—are unravelled from roll92.

Roll 92 feed is like unsuitable for corrugated cardboard material, whichembodies a laid flat set in production.

However, roll feed might be tenable for single layer sheet or card orsynthetic plastics, or even corrugated plastics where corrugations runparallel to the roll axis.

A sufficiently large roll diameter is envisaged to avoid materialadopting a set curvature.

Carton Construction (Pre-Bag Insertion)

FIGS. 9A through 9H detail alternative BIB construction and/or(pre-)assembly—independently of and prefacing bag introduction.

Generally, carton 11 is almost fully formed before bag 12 is insertedand collar 14 attached.

An assembly sequence comprises:

-   -   fold carton blank 11, bringing side panels 46 around to form        open-ended wrap 47;    -   (edge) seal side panels 46 together, using tab 19;    -   fold down top flaps 56, 42, 48 and seal in place;    -   insert bag 12 into carton 11 through open carton bottom;

{in practice, a carton collar could be lowered upon an inflated bag}

-   -   attach collar 14 to bag 12 through carton aperture 43;    -   close bottom flaps 57, 58 and seal in place.

Optionally, a pre-fabricated handle could also be fitted upon thecarton—as shown in FIG. 9G.

Alternatively, an integrated handle and collar top-plate could befitted—as shown in FIG. 9H.

Carton Construction Around Infated/Filled Bag

FIG. 10 shows an alternative BIB assembly of bag 12 pre-inflation/filland carton 11 build around it.

Sub-Assembly Construction

FIGS. 11 A through 11 C show sub-assembly from a bag roll 91 andindividual carton blank elements 41.

Each successive individual bag 51 is overlaid with a respective cartonblank 41.

Carton 41 is then folded in half around bag 51 until side panels 46 lieadjacent each other.

Carton side tab 19 is then glued or otherwise secured to adjacent sidepanel 46 edge.

Finally, collar 14 is attached to bag 51 and carton 41 to secure theseelements together.

FIG. 12 shows a stack of multiple individual BIB sub-assemblies 20.

Bracing Sleeve Insertion

FIGS. 13A through 13C illustrate insertion of bracing sleeve 16 intocarton 41.

Bracing sleeve 16 may be of toughened cardboard material or corrugatedas detailed in FIG. 13C.

Bracing sleeve 16 is preferrably profiled to nest within carton 41 bodyand provide extra strength at the edges and corners—as illustrated inFIG. 13B.

Corrugated Carton

The entire carton body 72 may be constructed from corrugated material—asshown in FIGS. 14A and 14B.

This may negate the need for an additional bracing sleeve inapplications where box robustness is of prime consideration.

Corrugated cartons 72 may also be useful in applications where thecarton does not require to be waterproof.

Collar Release Valve

FIGS. 15A and 15B illustrate how collar 14 recess may act as a safetyrelease valve when the BIB is dropped.

As a carton 41 is crushed from beneath, internal bag 51 is forcedupwards.

This forces out recess panel 73 which in turn pushes out attached collar14 with intrained bag neck 52.

As can be seen from FIG. 15B bag 51 then has more room in which to moveaway from the crushed carton below.

This may mean bag 51 can stay intact despite carton 41 crush.

Cushion Pad

A cushion pad 74 may be accomodated within carton 41 as shown in FIG.16.

This cushion pad 74 may be filled with air and placed on top of bag 51,adjacent the underside of recess panel 73.

As air or gas is more readily compressed than liquid, this cushion pad74 may crush before bag 51 liquid contents.

Integrated Bag & Collar

A bag may be integrated with a collar 82.

This may then be inserted into a carton 83 as shown in FIG. 17.

Carton 83 is provided with an opening 84 into which bag 82 is fed untilattached collar seals opening 84.

Collar & Bag Restraint

Collar 14 and entrained bag neck 52 are restrained from rotationalmovement by carton 41 recess profile.

Thus, as a screw cap 62 is applied, the resulting torque does not twistthe collar 14 or bag 51 inside the carton 41—as illustrated in FIG. 18.

Moulded Plastic Carton

FIGS. 19A and 19B show a variant carton 93 configured from a mouldedplastics sheet.

Collar 14 is thus integrated into the carton 93 form, negating the needfor attachment of an additional collar 14 element.

Other features may also be moulded into a plastic carton blank.

FIGS. 20A and 20B show a variant of the above with a plastic handlecut-out incorporated into carton 94.

‘Mix and Match’ Features

Generally, in the embodiments, where feasible and appropriate, featuresmay be selectively ‘mixed and matched’ to suit circumstances—albeit itis not feasible to describe every such feature combination.

Component List

11 box/carton

12 bag

13 handle

14 collar

15 cushion floor

16 bracing sleeve

17 stacking plate

18 tie band

19 side tab

20 sub-assembly

30 final assembly

40 cassette store

41 carton

42 top flap

43 neck aperture

44 handle aperture

45 side edge

46 end flaps

47 wrap

48 top closure flap

49 top flap corner edge fold

50 cassette store

51 bag element

52 bag neck

55 bag web

56 top closure side flaps

57 bottom side flaps

58 bottom end flaps

60 cassette store

61 collar aperture

62 cap

70 cassette store

71 sub-assembly web

72 corrugated carton

73 recess panel

74 cushion pad

80 conveyor bed

81 conveyor guides

82 integrated bag & collar

83 carton

84 opening

90 handle station

91 bag roll

92 carton roll

93 moulded carton

94 moulded carton with handle

100 sub-assembly line

110 inflation test station

111 valve cap

112 feed pipe

113 air pressure supply

114 rotary (swivel) connector valve

120 conveyor

130 end flap closure station

140 contents fill station

150 erect BIB

1. A BIB carton assembly process comprising the steps of: wrapping acarton (41) element around a bag (51) element and securing thesetogether, with a locating retention collar (14), to create asub-assembly (20), capable of being flat-packed for efficient transportor storage.
 2. A BIB carton assembly process of claim 1, furthercomprising the step of: securing a handle (13) to sub-assembly (20). 3.A BIB carton assembly process of claim 1, wherein locating retentioncollar (14), is integrated with a handle (13) element.
 4. A BIB cartonassembly process of claim 1, further comprising the steps of: inflatingand/or filling sub-assembly (20), by supporting collar (14), to allowbag (51) inflation and/or fill and attendant surrounding carton (41)configuration; and completion by closure and sealing of top (56,42, 48)and bottom (57,58) carton flaps.
 5. A BIB carton assembly process ofclaim 4, further comprising the step of: injecting air into bag (51), toact as a leak test, prior to contents fill.
 6. A BIB carton assemblyprocess of claim 1, further comprising the step of: erectingsub-assembly (20) into a completed pack after transfer to a remote fillline.
 7. A BIB carton assembly process of claim 1, further comprisingthe step of: erecting sub-assembly (20) into a completed pack at a localfill line.
 8. A BIB carton assembly process of claim 1, furthercomprising the step of: erecting sub-assembly (20) into a completed packpreparatory to filling.
 9. A BIB carton assembly process of claim 1,further comprising the steps of: erecting sub-assembly (20), byselective holding and folding of carton (41) flaps; sealing top (56,42,48) and bottom (57,58) carton flaps ; and inflating and/or filling bag(51).
 10. (canceled)
 11. A BIB carton assembly machine, with wrap meansto wrap a carton (41) element around a bag (51) element and secure thesetogether, with a locating retention collar (14), to create asub-assembly (20).
 12. A BIB carton assembly machine of claim 11, withsecuring means to secure a handle (13) onto sub-assembly (20).
 13. A BIBcarton assembly machine of claim 11, with collar fitting means to fit anintegrated locating retention collar (14), and handle (13) element. 14.A BIB carton assembly machine of claim 11, with further means to inflateand/or fill sub-assembly (20), by supporting collar (14), and allowingbag(51) inflation and/or fill and attendant surrounding carton (41)configuration; and means to close and seal top (56,42, 48) and bottom(57,58) carton flaps.
 15. A BIB carton assembly machine of claim 14,with further means to inject air into bag (51), to act as a leak test,prior to contents fill.
 16. (canceled)
 17. (canceled)
 18. (canceled) 19.(canceled)
 20. (canceled)
 21. (canceled)
 22. (canceled)
 23. (canceled)24. (canceled)
 25. (canceled)
 26. (canceled)
 27. A BIB carton assemblyprocess comprising the steps of: erecting a carton element with aprofiled opening, inserting a collar element with attached bag elementinto said opening, such that the bag is disposed inside the carton andthe collar secures the bag and carton elements together.
 28. A BIBcarton assembly process of claim 27, wherein the collar is integratedwith the bag.
 29. A BIB carton assembly process of claim 27, wherein bagand collar elements are attached in a pre-assembly step.
 30. (canceled)31. (canceled)
 32. (canceled)
 33. (canceled)
 34. (canceled) 35.(canceled)
 36. (canceled)
 37. (canceled)
 38. (canceled)